Automated article covering method and apparatus

ABSTRACT

The present invention provides a method for automatically covering an article with covering material and automatically tucking the material into a surface of the article.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation-in-part of U.S. application Ser. No.10/234,630, filed Sep. 4, 2002, which is relied on and incorporatedherein by reference.

BACKGROUND

The present invention relates generally to systems and methods formanufacturing covered articles.

Examples of reinforced materials are well-known in the art, includingU.S. Pat. No. 5,728,458 to Sweeney entitled “Light-Weight High-StrengthComposite Pad” and U.S. Pat. No. 5,209,968 to Sweeney entitled“Composite Structure With Waste Plastic Core And Method of Making Same,”both of which are incorporated herein by reference. These examplesdisclose the use of core materials coated with reinforcing layers formulti-use pads, equipment pads, building panels, and other applications.

Typically, these prior art reinforced layered structures are formed bymanual covering processes such as wrapping a core, trimming excesswrapping material, and attaching the material to or into the articlewith adhesive, physical bindings, or direct insertion into the articlecore. These manual steps can require a number of individuals, limit thequantity of articles that can be manufactured in a given time frame, andresult in inconsistent products. Accordingly there is a need to automatethe covering of articles.

The present invention answers this need by providing a coveringapparatus and method that automates the covering process formanufacturing articles.

SUMMARY OF THE INVENTION

The present invention provides an apparatus and method for coveringarticles. In embodiments of the invention, covering, trimming, and/ortucking of material into a core material is automated.

In an embodiment of the invention a conveyor system is provided fortransporting an article to covering, trimming and/or tucking stations tocover the article.

In an embodiment of the invention a fibrous fabric is tucked into a corematerial comprising expanded polystyrene (EPS) foam, moldable into anydesired shape. In further embodiments, additional material layers may beapplied or injected on and/or beneath the covering material to achievedesired reinforcing characteristics.

The present invention further provides a system and method formanufacturing reinforced articles with a core material covered with acovering material by injecting a desired compound or mixture between thecore material and covering material to create an inner reinforcinglayer.

In another embodiment of the invention, an automated covering station isprovided wherein covering material is dispensed for surrounding anarticle core. In one embodiment, the core material is covered by thedispensed material as the core drops through a slot in a covering tableacross which the covering material is dispensed.

In a further embodiment of the present invention, an automated tuckingstation is provided on a conveyor system for tucking one or moreportions of the covering material into the core material. In someembodiments, the tucking apparatus includes parallel pairs of horizontaland vertical tucking apparatuses for plunging covering material into thecore.

In another embodiment of the present invention, a corner trimmingstation with an automated pincher and welder is provided for trimmingexcess fabric at the corners of the covered core material by pulling andwelding the excess corner fabric.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a cross-sectional view of a reinforced article in anembodiment of the present invention.

FIG. 2 is a perspective view of a bottom surface of a core material in astack of core materials with receiving channels being burned at areceiving channel burning station in an embodiment of the presentinvention.

FIG. 3 is a top perspective view of a core material and coveringmaterial being positioned thereon at a covering material template tablein an embodiment of the present invention.

FIG. 4 is a top perspective view of a covering material tucking stationin an embodiment of the present invention.

FIG. 5 is a perspective view of a tucking apparatus including anautomated tucking needle and plunger in an embodiment of the presentinvention.

FIG. 6 is a perspective view of an excess fabric weld trimming stationincluding pinchers, weld holders, and weld blade in an embodiment of thepresent invention.

FIG. 7 is a top perspective view of a four corner automated weldtrimming apparatus in an embodiment of the present invention.

FIG. 8 is a top perspective view of a reinforcing layer injectionstation in an embodiment of the present invention.

FIG. 9 is a perspective partial cut-away view of a covered core materialbeing injected with an inner reinforcing layer mixture in an embodimentof the present invention.

FIG. 10 is a texturizing station in an embodiment of the presentinvention.

FIG. 11 is a top perspective view of a core material covering, trimmingand tucking conveyor apparatus in an embodiment of the presentinvention.

FIG. 12 is a top perspective view of an automated covering station in anembodiment of the present invention.

FIG. 13 is a top perspective view of a magazine cylinders apparatus ofan automated covering station in an embodiment of the present invention.

FIG. 14 is a partial perspective view of a core material and fabriclowered beneath a fabric table of an automated covering station in anembodiment of the present of the invention.

FIG. 15 of the is a partial perspective view of the trimming apparatusof an automated covering station prior to trimming the corner of acovered core material in an embodiment of the present invention.

FIG. 16 is a partial perspective view of the trimming apparatus of anautomated covering station during trimming of the corner of a coveredcore material in an embodiment of the present invention.

FIG. 17 is a top perspective view of a horizontal tucking apparatusstation in a conveyor apparatus with retracted tucking cylinders in anembodiment of the present invention.

FIG. 18 a the top perspective view of a horizontal tucking apparatusstation in a conveyor apparatus with tucking cylinders in loweredoperation in an embodiment of the present invention.

FIG. 19 is a top perspective view of a vertical tucking apparatusstation in a conveyor apparatus with retracted tucking cylinders in anembodiment of the present invention.

FIG. 20 is a top perspective view of a vertical tucking apparatusstation in a conveyor apparatus with tucking cylinders in loweredoperation in an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention provides a reinforced article and system andmethod for making the same. Those of ordinary skill in the art willappreciate that an embodiment described herein including an expandedpolystyrene (EPS) foam core material with a fabric covering material andcement mixture reinforcing layer is by way of example only, and avariety of alternative materials could be used. In this regard,exemplary covering materials may include fabric, fibrous wrap, webs,mesh, glass mats, paper, and any other types of synthetic or naturalfibrous material that is pregnable by a desired reinforcing layer. Corematerials include foamable materials such as polyurethane,polyisocyanurate, EPS, other rigid foams, plastics, corks, wood,synthetic polymers, and similar rigid core materials. Those of ordinaryskill in the art will further appreciate that such core materials may bemolded into virtually any shape or size as may be desired for thereinforced article. The reinforced mixture layer may include mixtures ofconcrete, plaster, epoxy, synthetic resins, polymers, paint,waterproofing compounds, glues, foams, and similar mixtures or materialscapable of injection between a core material and covering material. Inthis regard, “injection” may include the deposit of the reinforcingmaterial by injection entirely through a core material at any desiredangle, or, alternatively, with an appropriate injection head, throughthe covering material, so as to deposit the reinforcing layer betweenthe covering material and core material.

Referring to FIG. 1, a cross section of reinforced article 5 is shown. Acore material 10 is surrounded by covering material 15. In an embodimentof the invention, covering material 15 includes fabric woven ornon-woven. An inner reinforcing mixture layer 20, including a cementmixture in one embodiment, is provided between the core material 10 andthe covering material 15.

Covering material edges 19 are tucked into tucking grooves 30 in thecore material 10. The tucked edges 19 keep the covering material 15tightly surrounding the core material. Further, the tucked edges 19 andtucking groove 30 maximize retention of inner reinforcing mixture layer20 between core material 10 and covering material 15.

In alternative embodiments, tucking of edges 19 may be replaced oraugmented by gluing or other adhesives, taping, stapling, sewing, heatbinding, and like methods for adhering edges 19 to the core material 10.

In an embodiment of the invention, the inner reinforcing mixture layer20 is injected between the core material 10 and covering material 15after the covering material 15 is secure with tucked edges 19 in tuckinggroove 30. As described subsequently, a needle head with a dispersionhole may be used for depositing the inner reinforcing mixture layer 20.

In an embodiment of the invention, the inner reinforcing mixture layer20 is injected as a slurry mixture, such as a cement mixture, concretemixture, plaster mixture, epoxy mixture, synthetic resin mixture,polymer mixture, paint mixture, or waterproofing mixture and the like,depending on the desired end use of the reinforced article. Suchmixtures are preferably metered to deposit such amounts as are necessaryto create a desired thickness and characteristics of the reinforcinglayer 20 and reinforced article 5. Accordingly, depending on theproperties of the mixture deposited for the inner reinforcing mixturelayer 20, such mixture is cured to provide the desired reinforcingcharacteristics of the mixture used.

In alternative embodiments of the invention, one or more outerreinforcing mixture layers 25 may be provided in reinforced article 5.Outer layer 25 may be the same or a different substance from inner layer20. In an embodiment of the present invention where the reinforcedarticle 5 is an equipment pad, both the inner layer 20 and outer layer25 are cured cement mixtures. However, optional outer layer 25 maycomprise one or multiple layers that include any materials with desiredcharacteristics for reinforced article 5. In embodiments of the presentinvention, the outer reinforcing mixture layer 25 includes concrete,plaster, epoxy, synthetic resins, polymers, paint, waterproofingcompounds, cement, glues, and the like. It will be understood that thisis only an exemplary list, and further appreciated that the curing ofany applied mixtures, such as slurry mixtures, may be desirable toachieve desired characteristics of the outer reinforcing mixture layer25.

In another embodiment of the present invention, an outer reinforcinglayer 25 includes a texture layer 50 (FIG. 10). In one embodiment of thepresent invention, the texture layer 50 includes a solid substance, suchas sand 710 (FIG. 10), but may include virtually any solid with desiredtexture and binding characteristics with outer layer 25.

In embodiments of the present invention where covering material 15 is afabric or other fibrous material, inner layer 20 and optional outerlayers 25 and texture layer 50, at least in part, impregnate thecovering material 15 to bind and create the desirable reinforced surfacelayers surrounding core material 10 of reinforced article 5.

Referring to FIG. 2, in an embodiment of the present invention, corematerial 10 includes inner reinforcing layer receiving channels 40.Where core material 10 is EPS foam, the receiving channels 40 are burnedat a receiving channel burning station 100.

The receiving channel burning station includes hot wire burners 105 onwhich the core material 10 is placed to burn the receiving channel 40.

The receiving channels 40 are burned on any surface of the core materialwhich will contact the inner reinforcing mixture layer 20 and besurrounded by covering material 15. For instance, the receiving channelsmay be burned along all surfaces of the core material 10, or along sidesurfaces 15, or top surfaces and side surfaces, or any combinationsthereof.

The receiving channels 40 permit greater deposition of the innerreinforcing mixture layer 20 than a mere flat surface. Accordingly, thedepths of the receiving channels 40 may be increased or decreased forthe desired purpose of the reinforced article 5 and reinforcingcharacteristics of the inner layer 20.

As shown in FIG. 2, the core material may be stacked as a plurality ofcore materials to burn receiving channels on multiple core materials' 10surfaces at once. The stack is rotated to each desired receiving channelburning surface for burning on hot wires 105. In this embodiment, itwill be appreciated that front and back surfaces may be burned withreceiving channels 40 by separating each individual core material 10from the stack to burn the desired surface.

Further, depending on the properties and material of the core material10, receiving channels 40 may be formed by alternative methods such ascutting, drilling and boring.

In an embodiment of the present invention for manufacturing a reinforcedpad, the receiving channels 40 are preferably burned into a top surface(not shown) and side surfaces of a core material 10 made of EPS foam.

Referring again to FIG. 1, with continuing reference to FIG. 2, theinner reinforcing mixture layer 20 of cement mixture forms a layer onthe top and side surfaces of the core material and between the coveringmaterial 15. In this embodiment, the covering material is preferablypregnable fibrous fabric and the tucked ends 19 sustain the innerreinforcing layer 20 around the top and side surface of the corematerial 10 to also promote deposition of the inner reinforcing mixturelayer 20 into the receiving channels 40 of the top and side surfaces. Inthis embodiment, the receiving channels 40 are preferably ⅛″ wide by ¼″deep.

Referring to FIG. 3, a covering material application station 200 isshown. In embodiments where optional receiving channels 40 are utilized,the core material 10 is covered with covering material 15 after formingthe receiving channels 40. Alternatively, where receiving channels 40are not desired, the covering material is applied prior to injection ofinner reinforcing mixture layer 20.

In an embodiment of the present invention, the covering materialapplication station provides proper alignment of fabric coveringmaterial 15. A fabric template 205 is sized to the shape of the corematerial 10 so that the core material is centered on the fabric coveringmaterial 15. The fabric application station 200 is preferably a lighttable wherein the fabric template includes a template periphery foraligning the fabric covering material 15.

Once the core material is centered on the fabric covering material 15,the flaps 17 of the fabric are folded over the core material 10.

Referring to FIG. 4, the core material 10 including the folded flaps 17of covering material 15 is placed in covering material tucking station300.

The tucking station 300 includes a conveyor belt 305 for directing aplurality of covered core materials to a tucking apparatus 320. As shownin FIG. 4, two pairs of tucking apparatuses 320 are used in oneembodiment of the invention to tuck flaps 17 into tucking grooves 30(FIG. 1) as folded edges 19 (FIG. 1).

On opposite sides of the conveyor belt 305, flap rail guides 310 areprovided for maintaining the folded flaps 17 in a desired positionagainst core material 10. The rail guides 310 terminate at flap folder315 as the covered core material 10 is directed at each opposite flap 17to tucking apparatus 320.

Referring to FIG. 5, and continuing reference to FIG. 4, tuckingapparatus 320 includes a groove perforation needle 325 and tuckingplunger 330. Each of the needle 325 and plunger 330 are automated so asto actuate a rapid up and down plunging movement.

After the flaps 17 are directed through the flap folder 315, the needle325 perforates the flap 17 and core material 10 to create a tuckinggroove 30 (FIG. 1) perforation line. A blunt plunger head 330 followsthe perforation needle 325 to tuck covering material edge 19 (FIG. 1)into tucking groove 30 (FIG. 1). In an embodiment of the invention, aplurality of tucking apparatuses 320 may be used to reinforce tucking ofthe covering material edge 19 into tucking groove 30. In otherembodiments of the present invention, multiple tucking apparatuses areimplemented to form multiple tucked grooves for additional tucking ofportions of the covering material 15 into the core material 10.

In further embodiments of the invention, where the core material 10 issquare or rectangular shaped, the covered core material 10 is rotated 90degrees following initial tucking on opposite flaps 17. Unfoldedopposite flaps 14 are folded and the covered core material similarlyplaced on conveyer 305 of the tucking station 300 to tuck flaps 14 withtucking apparatus 320. In such embodiment, the top and four sidesurfaces of the core material 10 are completely covered by coveringmaterial 15 and all four edges of the fabric covering material 15 aretucked into the bottom surface 11 of the core material 10.

Referring to FIG. 6, in an embodiment of the invention with fabriccovering material 15 covering a corner 12 of the core material 10, andadjacent sides of the covering material tucked into a surface of thecore material 10, excess fabric corner 16 will result at corner 12.

In embodiments of the invention, it is desirable to trim the excessfabric corner 16 at a corner weld and trimming station 500. The cornertrimming station 500 includes actuated pinchers 505 that pinch excessfabric corner 16 and subsequently pull the excess fabric corner 16outward from the core material corner 12. Corner weld holders 510actuate to pinch and hold the excess fabric corner 16 at a point nearthe core material corner 12. An automatic trim weld blade 515 isactuated toward the pinched excess fabric corner 16 and the weld blade515 welds the excess fabric corner 16, such as a fibrous woven ornon-woven fabric, to create a welded tight, trimmed edge while theexcess fabric corner 16 is burned off and discarded. In some instances,additional trimming, such as by hand, of the fabric welded corner may benecessary to achieve a smooth welded corner edge.

Referring to FIG. 7, in an embodiment of the invention wherein thereinforced article 5 is square or rectangular shaped, the cornertrimming station 500 includes four sets of pinchers 505, weld holders510, and weld blades 515. In this embodiment, the covered core material10 is placed so that each corner is positioned between each set ofpinchers 505, weld holders 510, and weld blades 515, to allow automaticwelding and trimming of all four corners at once.

In a further embodiment, a plurality of covered core materials may bestacked to permit trimming of a plurality of stacked corners 12simultaneously.

Referring to FIG. 8, a reinforcing layer injection station 600 isdepicted with an injector 620 connected to a mixture supply line 630.

In an embodiment of the present invention, the injection station 600includes a conveyor 602 to provide automated injection of a plurality ofcovered core materials 10.

In a further embodiment of the present invention, square or rectangularcovered core materials 10 are stacked at a stacking partition 605 thataligns the stacked covered core material 10 for positioning on theconveyor 602 to the injector 620.

An indexer 610 is actuated in the line of conveyor movement toward thebottom covered core material 10 in the stack. The indexer 610 strikesthe bottom covered core material 10 from the stack to propel it out ofthe stack and along the conveyor toward the injector 620. Gravity causesthe remaining covered material 10 in the stack to move downward alongthe partition 605 when the indexer 610 retracts in a reverse directionfrom the movement of the conveyor 602.

It will be appreciated that in an embodiment of the present inventionthe covered core material propelled from the stack is covered facedownand the reverse face, facing upward, includes the bottom surface 11tucked portions. Accordingly, the tucked face is exposed toward theinjector 620.

The indexer 610 and injector 620 are in timed synchronization so thatthe indexer pushes the next covered core material 610 forward as theinjector 620 lifts up and down to receive and pin the covered corematerial in the injector. Metal injector guide 622 preferably holds thecovered core material in position for injection. Following injection ofthe inner reinforcing layer 20, the injection guides 622 retract upwardto permit the next indexed covered material into the injector 620.

Referring to FIG. 9, with continuing reference to FIG. 8, the injectorincludes an injection needle 625 and retracting needle arm 621. As thecovered core material 10 is received by injector 620, needle arm 621 andneedle 625 are lowered through the core material 10 until injectionneedle 625 is positioned so that injection hole 628 is positionedbetween the surface of the core material 10 and the covering material15. The reinforcing mixture 21, such as cement slurry, is provided by amixture feed line 630 connected to injection needle 625. The mixture 21is injected in a desired metered amount, depending on the desiredcharacteristics and thickness of the inner reinforcing layer 20.

Referring again to FIG. 8, in an embodiment of the invention, theinjector 620 includes a vacuum base that removes excess water from themixture 21 (FIG. 9) to form inner reinforcing layer 20 between thecovering material 15 and the core material 10. In an additionalembodiment, the injected mixture 21 includes a 1:1 cement/water ratio topromote dispersion. The increased water ratio, compared to typicalcement mixtures, provides a better dispersion consistency for ventingthe reinforcing layer 20. The vacuum action acts to dewater the mixture21 to solidify the injected cement mixture 21.

Once the desired inner reinforcing layer 20 is provided by the injectionof mixture 21, the injector, including the injector guide 622,retractable needle arm 621 and needle 625, are lifted upward to permitthe injected article 5 to be removed. As disclosed, the next coveredcore material 10 is indexed forward and the injector, including injectorguide 622, needle arm 621 and injector needle 625, lowered to pin thecovered core material 10 and repeat the process.

The reinforced article with inner injection layer 20 may be cured asdesired.

In one embodiment, the covered core material 10 including the injectedinner reinforcing layer 20 is further coated with an outer reinforcingmixture layer 25 (FIG. 1). The application of an outer reinforcingmixture layer 25 is well known in the art, and may include automated orby-hand application of a desirable outer reinforcing layer 25 to theoutside of the covering material 15.

Referring to FIG. 10, in another embodiment of present invention, asolid textured layer 50 (FIG. 1) is further applied to the outerreinforcing mixture layer 25. At texturizer station 700 the covered corematerial 10, including inner and outer mixture layers, is moved alongconveyor 701 beneath pad texturizer 705. Sand, or other desired solidtexture substance, is disbursed by the rotating pad texturizer 705 tocreate a desired textured surface on reinforced article 5 (FIG. 1).

Referring to FIG. 11, in an alternative embodiment, core materialcovering, fabric trimming and fabric tucking operations are automatedwith computer settings and a conveyor system.

In the exemplary embodiment, a fabric dispenser provides fabric 15 froma fabric roll 815 to an automated covering station 900 and automatedtrimming station 1000. Fabric 15 is provided to the core material 10 atthe covering table 905 and the fabric corners are trimmed beneath thetable 905.

After the fabric 15 is applied to the core material 10, the covered corematerial 10 is conducted on a conveyor belt 1200 to the tucking station1100. The tucking station 1100 includes a pair of horizontal plungingapparatus 1105 and a pair of vertical plunging apparatus 1110 forautomatically tucking the fabric 15 into and along each side of the corematerial 10.

With reference to FIG. 12, the fabric dispenser 810 includes a fabricroll 815 that dispenses fabric 15 across the automated covering table905. The fabric dispenser 810 rolls out the desired length of fabric 15based on computer programmable settings. Such programs settings are wellknown in the art.

The fabric 15 is dispensed between a raised stack 910 of core material10 and a trimming station elevator 915. A “hot wire” powered by amoveable cylinder is lowered to burn the fabric 15 so it is cut to thedesired length. It will be appreciated that a variety of alternativecutting apparatuses may be used to cut the fabric.

In a fabric 15 receiving position, the elevator 915 is generally levelwith the covering table 905. The elevator 915 includes a vacuum thatsecures the fabric 15 across the elevator. As a safety mechanism, aphoto eye is provided approximately two inches past the elevator 915 todetect if the fabric 15 does not come within view. In the event thatfabric 15 is not detected, the system is stopped for troubleshooting.

With reference to FIG. 13, the elevator 915 and fabric 15 are raisedbeneath the bottom core material 10 of the raised magazine assembly 911.The magazine dispenser control apparatus 920, such as a moveablecylinder with retractable stabbers 925, releases a core material article10. It will be appreciated that moveable cylinders include hydrauliccylinders, pneumatic cylinders, electric actuators and the like.

The elevator 915 is lowered with the core material 10 and fabric 15, andthe stack 910 adjusts so that the next article 10 in the magazineassembly 911 is engaged by the stabbers 925 until the next cycle. In oneembodiment, a photo eye is positioned on the magazine assembly 911 todetect if there are not at least two core materials 10 in the magazine.Because of the ease of loading before the magazine is completely empty,the system will not initiate if there are less than two articlesdetected. The switch may be bypassed to use all of the articles bycovering the photo eye.

As shown in FIG. 14, the elevator 915 is lowered beneath the fabricreceiving table 905. As the fabric 15 and core material 10 pass throughthe elevator slot 907, the edges of the fabric 15 that extend beyond theedges of the core material 10 fold vertically against the sides of thecore material 10 and the slot 907.

Referring to FIG. 15, the elevator 915 supporting a rectangular coveredcore material 10 stops centered between four sets of corner trimmingpinchers 1005. Each pincher set 1005 is generally “L” shaped with ahorizontal portion 1009 extending over the top of the covered article 10and a vertical portion 1007 extending along a side of the coveredarticle 10. Each pincher set closes at a respective corner 12 of thecovered article 10 so that the vertical portion 1007 of a pincher set1005 folds the fabric 15 around the sides of the core material 10 andthe horizontal portion 1009 folds fabric 15 over a portion of the top ofthe article 10. The pinchers also hold excess fabric 15 at each corner12 for trimming.

Referring to FIG. 16, a long cylinder with a small gripper 1120 indexesto each of the four corners 12 and the gripper 1120 grabs and holds theexcess fabric 15 at the corner 12. A “hot wire” between the jaws of thepinchers sets 1005 is energized while the fabric 15 is being held by thegrippers 1120. The “hot wire” cuts the excess fabric 15 from the corner12 while simultaneously welding the fabric around the corner 12 of thearticle 10. The long cylinders for the grippers 1120 retract to pull thecut off fabric away from each of the corners 12.

In an embodiment of the invention, a cooling nozzle 1125 is provided ateach corner 12 where the pinchers 1005 conduct trimming operations.Pressurized air is provided to the corner 12 following the weld cut andremoval of the excess fabric 15 from the corner 12 to cool andstrengthen the weld.

In a further embodiment, a debris removal air nozzle is also provided ateach corner 12 of the trimming station to blow away the excess fabric 15from the grippers 1120. After the grippers 1120 retract with the cutexcess corner fabric 15, each gripper 1120 is opened and the debrisremoval nozzle provides a burst of air to blow away fabric 15 debrisfrom the machine.

The folding pinchers 1005 are subsequently opened to release the article10 with fabric folded over the bottom face and side surfaces. Theelevator 915 is raised up to the height of the covering table 905 untilthe covered article 10 is beneath the stack 910 of core material 10 inthe magazine assembly 911.

A pressurized air nozzle subsequently blows air to propel the article 10out from underneath the magazine 911 and on to a conveyor 1200 forcarrying the article 10 to the tucking station 1100. As a safetyprecaution, a photo eye is also used to detect if the article 10 doesnot enter and/or leave the elevator 915 and covering table 905.

The cycle restarts for covering and fabric trimming the next article 10at the bottom of the stack 910 in the magazine assembly 911.

Referring to FIG. 17, as it is being blown from the covering table, thearticle 10 is carried on a first conveyor belt 1205 (FIG. 18) to theautomated tucking station 1100. With reference to FIGS. 18 and 19, thetucking station 1100 includes a first set of horizontal automatedtucking apparatuses 1105 and a second set of vertical automated tuckingapparatuses 1110.

Referring to FIG. 20, in an embodiment of the invention, a tuckingapparatus 1105 and 1110 includes four plungers 1150 and a rollingmechanism 1158. Along an edge of the top surface of the covered article10, the plurality of plungers 1150 are actuated up and down by a tuckingcylinder as the tucking apparatus 1105 and 1110 rolls along the edge inwhich fabric is being tucked.

With further reference to FIGS. 17–19, along parallel opposite sides ofthe top fabric covered article 10, each of the horizontal tuckingapparatuses 1105 is actuated forward and/or backward to tuck the loosefabric along the top into and along a horizontal edge of the article 10.Similarly, along parallel opposite vertical sides of the covered article10, the vertical apparatuses 1110 are actuated forward and/or backwardto tuck the loose fabric into the article 10.

In the described embodiment, the fabric 15 is first tucked horizontallyinto opposite edges of the top surface of the article 10. Following thehorizontal tucking operation, the article 10 is conveyed to verticaltucking station for the vertical tucking operation. Those of ordinaryskill will appreciate that the sequence of horizontal and verticaltucking may be reversed, and that in other embodiments, the tuckingoperations may be combined, as with programmable timing logic.

Referring to FIG. 18, in one embodiment, the article 10 is blown awayfrom the folding station 900 (FIG. 11) on to the conveyor 1205 to thehorizontal tucking station. A first automated stop 1170 or set of stopsis pivoted up from the plane of the first conveyor belt 1205 to blockand hold the article for horizontal tucking operations. In alternativeembodiments, the stop(s) 1170 could be actuated from other positionssuch that the stop 1170 blocks the path of the article 10 to hold it inplace.

After reaching the first stops 1170, a moveable guide rail 1180 isextended to a side of the article 10 to secure it in place. The guiderail 1180 is attached to a cylinder and presses the article 10 against araised edge 1160 along the conveyor belt 1205 on the opposite side ofthe article 10 to create a tight fit for consistent tucking of allarticles 10. The conveyor 1205 is stopped on actuation of the moveableguide rail 1180.

The horizontal tucking apparatuses 1105 are positioned opposite of oneanother on the horizontal tucking station frame 1104. The frame 1104lowers to position the plungers 1150 (FIG. 20) near the article 10 forplunging. The frame 1104 raises to move the tucking apparatuses 1105away from the article 10, such as accepting and releasing the article 10for tucking.

After the guide rail 1180 secures the article, the horizontal tuckingstation frame 1104 is lowered to position the tucking apparatuses 1105along horizontal tuck lines of the loose fabric 15 on the top surface ofthe article 10.

With continuing reference to FIG. 20, the rolling mechanisms 1158 of thetucking apparatus contact the article 10 when the frame 1104 is lowered.The tucking apparatus 1105 moves laterally by pneumatic actuation alongthe frame 1104 as the frame 1104 acts as a track to maintain the tuckingapparatus 1105 and plungers 1150 on the tuck line. The plungers 1150 areactuated by cylinders to move rapidly up and down to tuck the fabric 15into the top surface of the article 10.

Following horizontal tucking, the horizontal stop 1170 is retractedupward and the conveyor 1205 is turned on. In one embodiment a secondconveyor belt 1207 is provided to the vertical tucking station. From thefirst conveyor 1205, and following retraction of the horizontal stops1170, the covered article with horizontal tucks moves to the verticaltucking station.

Referring to FIG. 19, a vertical station stop 1185 is actuated to stopthe article at the desired position on the second conveyor 1207 at thevertical station. Like the horizontal tucking apparatuses 1105, thevertical tucking apparatuses 1110 are positioned on a vertical tuckingstation frame 1106. However, the set of vertical apparatuses 1110 arepositioned perpendicular with respect to the horizontal apparatuses1005. Accordingly, the remaining loose fabric 15 on the top surfaceedges of the article 10 is vertically tucked.

Mechanically, the vertical tucking operation is identical to thehorizontal tucking apparatus operation.

Following the vertical tucking operation, the vertical station frame1106 and vertical guide rail 1181 is retracted. The second conveyor belt1207 is then turned on and the vertical station stops 1185 moved fromthe path of the covered article 10. The second conveyor 1207 transportsthe covered article 10 from the vertical tucking station for removalfrom the system, or, alternatively, carries the article 10 on furtherconveyor(s) for additional processing, such as the application ofreinforcing material.

As a safety precaution and to increase consistency, in one embodiment ofthe present invention photo eyes are positioned next to each of thehorizontal and vertical station stops. The tucking apparatuses will notstart unless the pad is detected in the proper position at each station.

In another embodiment, a program switch is also provided that restrictsoperation of the first conveyor belts from the folding and trimmingstation to the horizontal tucking station until at least one cycle ofthe automated tucking and trimming station occurs. In this andalternative embodiments, another program switch is also provided toprevent propulsion of the article following trimming from the elevatorarea to the horizontal tucking station if the tucking operations are inprocess. Similarly, the second belts will not be turned on the articletransported from horizontal tucking station to the vertical tuckingstation if an another program switch senses vertical tucking operationsare not complete. In such embodiments, any detected problem must becorrected and the system reset for operations to resume.

Accordingly, while the invention has been described with reference tothe structures and processes disclosed, it is not confined to thedetails set forth, but is intended to cover such modifications orchanges as may fall within the scope of the following claims.

1. A method for covering an article comprising: dispensing a coveringmaterial from a dispenser over a vertically retractable elevator;releasing an article from a magazine assembly holding a pluralityarticles on to the covering material and the elevator; lowering theelevator through a slot to fold the covering material upward around oneor more sides of the article; and tucking one or more free edges of thecovering material directly into the article.
 2. The method of claim 1further comprising trimming and welding loose covering material over oneor more corners of the article.
 3. A method for covering an articlecomprising: providing an article with a top surface, bottom surface andfour side surfaces, wherein covering material surrounds a bottom surfaceand the four side surfaces and free ends of the covering material extendover the top surface; conducting the article on a conveyor to a firsttucking station, wherein the first tucking station includes at least twoautomated first tucking station plunging apparatuses positioned paralleland across from one another over a respective parallel edge of the topsurface of the article; plunging opposite and parallel free ends of thecovering material into the top surface of the article with the at leasttwo automated first tucking station plunging apparatuses along theparallel edges of the top surface of the article; conducting the articleon a conveyor to a second tucking station, wherein the second tuckingstation includes at least two automated second tucking station plungingapparatuses positioned parallel and across from one another over an edgeof the top surface of the article that is perpendicular to the paralleledges along which the loose ends of covering material were plunged atthe first tucking station; and plunging opposite and parallel remainingfree ends of the covering material into the top surface of the articlewith the at least two automated second tucking station plungingapparatuses along the parallel edges of the top surface of the article.4. The method of claim 3 wherein the first and second station plungingapparatuses each include a plurality of automatically actuated plungers.5. The method of claim 4 wherein the first and second station plungingapparatuses each include rollers for moving along a tuck line of theplungers.
 6. The method of claim of 5 wherein each of the first andsecond station plunging apparatuses is laterally actuated by a cylinderselected from the group consisting of pneumatic and hydraulic cylinder.7. The method of claim 4 wherein the automatically actuated plungers areconnected to one or more hydraulic or pneumatic cylinders.